Health monitoring pneumatic deicer

ABSTRACT

A monitored deicing system is disclosed. The monitored deicing system may have a pneumatic deicer and a signal wire running through the pneumatic deicer. The signal wire may break in response to a failure of the pneumatic deicer, such as a torn boot seam. A health monitor may check the continuity of the signal wire in order to provide an alert upon detecting such a failure.

FIELD

The present disclosure relates generally to a pneumatic deicers, andmore specifically to pneumatic deicers with built-in health monitoringfunctionality.

BACKGROUND

A pneumatic deicer may include layers of fabric sewn together alongstitchlines in a configuration to create a series of tubes along anaircraft structure. The tubes may be inflated to dislocate ice from theaircraft structure. However, due to wear, the stitchlines attaching thelayers of fabric creating the series of tubes may break. As a result,the series of tubes may lose their shape as the stitchlines fail.Moreover, following the failure of a first stitchline, the failure ofsubsequent additional stitchlines often follows as the hoop stressincreases. Often several stitchlines fail before crew and/or maintenancepersonnel become aware of the failures, such as during an in-flighticing situation when the pneumatic deicer fails to work effectively.

SUMMARY

The forgoing features and elements may be combined in variouscombinations without exclusivity, unless expressly indicated hereinotherwise. These features and elements as well as the operation of thedisclosed embodiments will become more apparent in light of thefollowing description and accompanying drawings.

A monitored deicing system is disclosed. The monitored deicing systemmay include a pneumatic deicer and a signal wire array including atleast one signal wire. The signal wire may be disposed through thepneumatic deicer and positioned to lose electrical continuity inresponse to a failure of the pneumatic deicer.

A method of operating a monitored deicing system is disclosed. Themethod may include attempting, by a health monitor, to pass anelectrical current through a signal wire disposed along a boot seam of apneumatic deicer, evaluating, by the health monitor, a continuity of thesignal wire in response to the electrical current, identifying, by thehealth monitor, that the signal wire lacks continuity in response to theevaluating, and determining, by the health monitor, that the boot seamhas broken in response to the identification that the signal wire lackscontinuity.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter of the present disclosure is particularly pointed outand distinctly claimed in the concluding portion of the specification. Amore complete understanding of the present disclosure, however, may bestbe obtained by referring to the detailed description and claims whenconsidered in connection with the drawing figures, wherein like numeralsdenote like elements.

FIG. 1 illustrates a monitored deicing system having a pneumatic deicer,one or more signal wires, and health monitor according to variousembodiments;

FIG. 2 illustrates a pneumatic deicer and one or more signal wiresinstalled on an aircraft structure and having boot seams orientedperpendicular to a chord line of the aircraft structure, according tovarious embodiments;

FIG. 3 illustrates a pneumatic deicer and one or more signal wiresinstalled on an aircraft structure and having boot seams orientedparallel to a chord line of the aircraft structure, according to variousembodiments;

FIG. 4 illustrates an example boot seam of a pneumatic deicer, accordingto various embodiments; and

FIG. 5 illustrates an example method of operating a monitored deicingsystem.

DETAILED DESCRIPTION

The detailed description of exemplary embodiments herein makes referenceto the accompanying drawings, which show exemplary embodiments by way ofillustration. While these exemplary embodiments are described insufficient detail to enable those skilled in the art to practiceembodiments of the disclosure, it should be understood that otherembodiments may be realized and that logical changes and adaptations indesign and construction may be made in accordance with this inventionand the teachings herein. Thus, the detailed description herein ispresented for purposes of illustration only and not limitation. Thescope of the disclosure is defined by the appended claims. For example,the steps recited in any of the method or process descriptions may beexecuted in any order and are not necessarily limited to the orderpresented. Furthermore, any reference to singular includes pluralembodiments, and any reference to more than one component or step mayinclude a singular embodiment or step. Also, any reference to attached,fixed, connected or the like may include permanent, removable,temporary, partial, full and/or any other possible attachment option.Additionally, any reference to without contact (or similar phrases) mayalso include reduced contact or minimal contact.

Furthermore, any reference to singular includes plural embodiments, andany reference to more than one component or step may include a singularembodiment or step. Surface shading lines may be used throughout thefigures to denote different parts but not necessarily to denote the sameor different materials.

As used herein, “aft” refers to the direction associated with thetrailing edge (e.g., the back end) of an aircraft structure. As usedherein, “forward” refers to the direction associated with the leadingedge (e.g., the front end) of an aircraft structure.

A first component that is “normally outward” of a second component meansthat a first component is positioned at a greater distance away from thesurface of the aircraft structure as measured along a vectorperpendicular to a tangent of the surface of the aircraft structure atthe location of the first component, than the second component. A firstcomponent that is “normally inward” of a second component means that thefirst component is positioned at a lesser distance away from the surfaceof the aircraft structure as measured along a vector perpendicular to atangent of the surface of the aircraft structure at the location of thefirst component, than the second component.

With reference to FIGS. 1 and 2, a monitored deicing system 1 mayinclude a pneumatic deicer 3, a signal wire array 7, and a healthmonitor 5. The pneumatic deicer 3 may deflate and inflate in order todislodge ice from aircraft structures such as flight control structures,airfoils, empennages, fuselages, wings, and any desired aircraft part.The signal wire array 7 may comprise one or more signal wires 4 (FIG. 2)disposed through the pneumatic deicer 3. In the event of a pneumaticdeicer 3 failure, one or more signal wires 4 (FIG. 2) of the signal wirearray 7 may break, losing electrical continuity (and becoming an opencircuit). A health monitor 5 may monitor electrical current(s) passedthrough the one or more signal wires 4 (FIG. 2) of the signal wire array7. In response to a signal wire 4 breaking, the electrical current mayhalt (the circuit including one or more signal wire 4 of the signal wirearray 7 and the health monitor 5 may become an open circuit), thusnotifying the health monitor 5 of the breakage. In response, the healthmonitor 5 may alert a crew or maintenance personnel of the breakage. Infurther embodiments, the health monitor 5 may selectively deactivatepart or all of a pneumatic deicer 3 in response to the breakage toprevent further failures, such as of portions of the pneumatic deicer 3not immediately affected by the indicated breakage.

A pneumatic deicer 3 may be disposed along an airfoil. For instance, thepneumatic deicer may be disposed along the leading edge of an airfoil,such as a wing and/or a horizontal stabilizer. In various embodiments,the pneumatic deicer 3 may be disposed along a suction side of anairfoil. Alternatively, the pneumatic deicer 3 may be disposed along apressure side of an airfoil. Moreover, the pneumatic deicer 3 may bedisposed along both a suction side and a pressure side of an airfoil. Inthis manner, any portion of an aircraft susceptible to ice buildup maybe equipped with a pneumatic deicer 3.

A signal wire 4 may be disposed through the pneumatic deicer 3. A signalwire 4 may comprise an electrically conductive fiber (“ECF”). The ECFmay comprise a carbon fiber filament. In further embodiments, the ECFmay comprise a wire. For instance, the ECF may comprise a fine diametermetal wire. The ECF may comprise a resistance wire, such as a wire madeof an alloy of nickel and chromium (e.g, nickel-chromium wire, or“nichrome wire”). Thus, the ECF may comprise any conductive filament,fiber, wire, or material, as desired.

A health monitor 5 may comprise an electronic device in electricalcommunication with the signal wire 4 and capable of detecting breakageof the signal wire 4. For example, the health monitor 5 may comprise acontinuity-testing device. The health monitor 5 may pass an electricalcurrent through one or more signal wire 4 of a signal wire array 7. Forinstance, the health monitor 5 may pass small DC current(s) through eachsignal wire 4 and may monitor the resistance presented to the current(s)by the wire(s). Alternatively, the health monitor 5 may pass small ACcurrent(s) through the signal wire(s) 4 and may monitor the impedancepresented by the wire(s). In further embodiments, the health monitor 5may pass momentary AC and/or DC current pulses through the signalwire(s) 4 to periodically assess an impedance and/or resistance of thesignal wire(s) 4. Thus, the health monitor 5 may comprise any signaland/or current delivering device whereby the continuity of a signal wire4 may be tested. For example, a health monitor 5 may have a processorand a tangible, nontransitory memory. The health monitor 5 may acceptvarious inputs, may provide various outputs and perform certain logicalprocesses in response to the inputs. The health monitor 5 may providevarious outputs in response to the logical processes. For example, thehealth monitor 5 may receive a request from other aircraft systems todetermine the continuity of a signal wire 4. The health monitor 5 mayoutput a small electrical current through a signal wire 4. The healthmonitor 5 may determine the continuity of the signal wire 4 in responseto the current, and may output a continuity status indication inresponse. For instance, outputting a continuity status indication maycomprise at least one of alerting a crewmember, providing an indicationof the status of the continuity of a signal wire 4 and/or signal wirearray 7 (e.g., all the signal wires 4) to another aircraft system,storing a continuity status indication, or storing a continuity statusindication for later communication to maintenance personnel.

With reference now to FIGS. 1-4, a pneumatic deicer 3 may comprisevarious components. For example, a pneumatic deicer 3 may comprise acovering layer 6, a forming layer 9, boot seams 10, and a base layer 8.Moreover, a pneumatic deicer 3 may comprise various orientations. Forexample, as illustrated in FIG. 2, a pneumatic deicer 3 may be orientedso that boot seams 10 lie perpendicular to the chord of an aircraftstructure 2 (e.g., “spanwise boot seams”). As illustrated in FIG. 3, apneumatic deicer 3 may be oriented so that boot seams 10 lie parallel tothe chord of an aircraft structure 2 (e.g., “chordwise boot seams”).

A base layer 8 may comprise a fabric layer. For instance, the base layer8 may comprise a substantially inelastic fabric. The base layer 8 mayhowever comprise any material as desired. In general, the base layer 8resists stretching and distorting during inflation and deflation of thepneumatic deicer 3. The base layer 8 may be disposed immediately atop anaircraft structure 2.

A forming layer 9 may comprise a fabric layer. For instance, the forminglayer 9 may comprise an elastic fabric. The forming layer 9 may howevercomprise any material as desired. In general, the forming layer 9stretches during the inflation and deflation of the pneumatic deicer 3.As such, the forming layer 9 and the base layer 8 may comprise differentmaterials. The forming layer 9 is disposed immediately atop the baselayer 8.

The forming layer 9 and the base layer 8 may be joined together. Thus,the pneumatic deicer 3 may comprise boot seams 10. Boot seams 10comprise stitching extending through the base layer 8 and the forminglayer 9 and holding the base layer 8 and the forming layer 9 together.The forming layer 9 and the base layer 8 may be joined together by aplurality of boot seams 10 spaced and arranged to form tube structuresfrom the union of the base layer 8 and the forming layer 9. The bootseams 10 may substantially seal the forming layer 9 and the base layer 8against fluidic leakage at each boot seam 10. As such, compressed fluid,for example, air may be pumped between the forming layer 9 and the baselayer 8. The forming layer 9 may expand in response to the compressedfluid. Because the boot seams 10 hold the forming layer 9 and the baselayer 8 together and substantially seal them together, a series ofridges (e.g., raised tubular structures) may form in the pneumaticdeicer 3 as the forming layer 9 expands, yet is stitched in union to thebase layer 8 along the boot seams 10. Each raised tubular structure maydislodge ice from the aircraft structure 2 in response the expansion ofthe forming layer 9. The relative difference in expansion in the forminglayer 9 near to and farther from each boot seam 10 further enhances thedislocation of ice from the aircraft structure 2.

The pneumatic deicer 3 may further comprise a covering layer 6. Acovering layer 6 may comprise a substantially elastic material. Thus,the covering layer 6 may exert a counter force to that exerted bycompressed fluid pumped into the pneumatic deicer 3 to expand theforming layer 9. Thus, the covering layer 6 may comprise a substantiallyelastic material whereby the forming layer 9 is compressed substantiallyflat upon the withdrawal of the compressed fluid. In this manner, as thepneumatic deicer 3 is deflated, the pneumatic deicer 3 may conform to ashape corresponding to that of the underlying aircraft structure 2. Thecovering layer 6 may further protect the forming layer 9 from damage,such as from puncturing by ice. In various embodiments, the coveringlayer 6 comprises rubber. For example, the covering layer 6 may compriseneoprene. However, the covering layer 6 may comprise any material asdesired.

The signal wire(s) 4 of the signal wire array 7 of the monitored deicingsystem 1 may be co-located with aspects of the pneumatic deicer 3. Forexample, a signal wire 4 may be disposed parallel to the boot seam 10.In further embodiments, a signal wire 4 may comprise stitchingimmediately to one side of the boot seam 10. In this manner, the signalwire 4 may be subject to breaking prior to the boot seam 10. In furtherembodiments, a signal wire 4 is co-located with the boot seam 10 so thatit will break substantially simultaneously with the boot seam 10. Instill further embodiments, a signal wire 4 may wrap the boot seam 10, ormay itself comprise the boot seam 10 or a portion of the boot seam 10.

With reference to FIG. 4, the boot seams 10 may comprise a main thread11 and a bobbin thread 12. A main thread 11 may comprise a structuralload bearing thread disposed through the forming layer 9. A bobbinthread 12 may comprise a structural load bearing thread disposed throughthe base layer 8. The bobbin thread 12 and the main thread 11 mayoverlap at least one of: substantially at the intersection of theforming layer 9 and the base layer 8 (e.g., “standard tension seam”), atthe surface of the forming layer 9 (e.g. “forming layer anchored seam”),or at the inward surface of the base layer 8 (e.g., “base layer anchoredseam”).

A signal wire 4 may be co-located with the boot seam 10, as mentioned.In various embodiments, the signal wire 4 may be a filament woven intothe bobbin thread 12. In further embodiments, the signal wire 4 may be afilament woven into the main thread 11. Similarly, a separate signalwire 4 may be woven into each of the bobbin thread 12 and main thread11. In further embodiments, the signal wire 4 may be the bobbin thread12, or the main thread 11, or both the bobbin thread 12 and the mainthread 11. The signal wire 4 may wrap the bobbin thread 12, for example,in a helical spiral. Similarly, the signal wire 4 may wrap the mainthread 11, for example, in a helical spiral. Moreover, a separate signalwire 4 may be wrapped around each of main thread 11 and the bobbinthread 12. Furthermore, a single signal wire 4 may comprise a singlehelix wrapping around the entire boot seam 10 (e.g., both main thread 11and bobbin thread 12). By wrapping the signal wire 4 around at least oneof the main thread 11 and the bobbin thread 12, a greater length ofsignal wire 4 is used than of the thread around which it is wrapped. Assuch, the structural load may be borne by the wrapped thread, ratherthan the signal wire 4, for example, in the instance that a signal wire4 having less tensile strength than the wrapped thread, is used. In thismanner, premature breakage of the signal wire 4 may be ameliorated,reducing signaling errors. In further embodiments, the signal wire 4 maybe sewn around the boot seam 10, again, ameliorating premature breakageof the signal wire 4, reducing signaling errors.

Each signal wire 4 of the signal wire array 7 is connected in electricalcommunication with the health monitor 5. For example, a signal wire 4may be terminated to lead wires connecting to the health monitor 5. Infurther embodiments, a signal wire 4 is terminated to thin polyimide busbars connecting to an airframe wiring harness which then connects to thehealth monitor 5.

With reference to FIGS. 1-4 and with further reference to FIG. 5, amonitored deicing system 1 may be operated according to various methods.For example, a method 500 of operating a monitored deicing system 1 maycomprise the following steps. Fluid may be pumped into a pneumaticdeicer 3 (Step 501). In various embodiments, the fluid comprises air.The pneumatic deicer 3 may inflate in response to the fluid (Step 502).A health monitor 5 may attempt to pass an electrical current through asignal wire 4 disposed along a boot seam 10 of the pneumatic deicer 3(Step 503). The health monitor 5 may evaluate a continuity of the signalwire 4 in response to the electrical current (Step 504). In response tothe electrical current failing to pass through the signal wire 4, thehealth monitor 5 may establish that the signal wire 4 lacks continuity(Step 505). In response to the signal wire 4 lacking continuity, thehealth monitor 5 may determine that the boot seam 10 has broken (Step506). Consequently, the health monitor 5 may provide an indicationdirecting that the fluid be pumped out of the pneumatic deicer 3 (Step507). In response, the pneumatic deicer 3 may deflate (Step 508).

Various benefits and advantages have been described herein with regardto specific embodiments. Furthermore, the connecting lines shown in thevarious figures contained herein are intended to represent exemplaryfunctional relationships and/or physical couplings between the variouselements. It should be noted that many alternative or additionalfunctional relationships or physical connections may be present in apractical system. However, the benefits, advantages, and any elementsthat may cause any benefit or advantage to occur or become morepronounced are not to be construed as critical, required, or essentialfeatures or elements of the disclosure. The scope of the disclosure isaccordingly to be limited by nothing other than the appended claims, inwhich reference to an element in the singular is not intended to mean“one and only one” unless explicitly so stated, but rather “one ormore.” Moreover, where a phrase similar to “at least one of A, B, or C”is used in the claims, it is intended that the phrase be interpreted tomean that A alone may be present in an embodiment, B alone may bepresent in an embodiment, C alone may be present in an embodiment, orthat any combination of the elements A, B and C may be present in asingle embodiment; for example, A and B, A and C, B and C, or A and Band C.

The foregoing features and elements may be combined in variouscombinations without exclusivity, unless expressly indicated otherwise.These features and elements as well as the operation thereof will becomemore apparent in light of the following description and the accompanyingdrawings. It should be understood, however, the following descriptionand drawings are intended to be exemplary in nature and non-limiting.

Systems, methods and apparatus are provided herein. In the detaileddescription herein, references to “various embodiments”, “oneembodiment”, “an embodiment”, “an example embodiment”, etc., indicatethat the embodiment described may include a particular feature,structure, or characteristic, but every embodiment may not necessarilyinclude the particular feature, structure, or characteristic. Moreover,such phrases are not necessarily referring to the same embodiment.Further, when a particular feature, structure, or characteristic isdescribed in connection with an embodiment, it is submitted that it iswithin the knowledge of one skilled in the art to affect such feature,structure, or characteristic in connection with other embodimentswhether or not explicitly described. After reading the description, itwill be apparent to one skilled in the relevant art(s) how to implementthe disclosure in alternative embodiments.

Furthermore, no element, component, or method step in the presentdisclosure is intended to be dedicated to the public regardless ofwhether the element, component, or method step is explicitly recited inthe claims. No claim element herein is to be construed under theprovisions of 35 U.S.C. 112(f), unless the element is expressly recitedusing the phrase “means for.” As used herein, the terms “comprises”,“comprising”, or any other variation thereof, are intended to cover anon-exclusive inclusion, such that a process, method, article, orapparatus that comprises a list of elements does not include only thoseelements but may include other elements not expressly listed or inherentto such process, method, article, or apparatus.

1. A monitored deicing system comprising: a pneumatic deicer; and asignal wire array including at least one signal wire disposed throughthe pneumatic deicer, and positioned to lose electrical continuity inresponse to a failure of the pneumatic deicer.
 2. The monitored deicingsystem according to claim 1 further comprising: a health monitor inelectrical communication with the signal array, whereby a continuity ofthe signal wire of the signal wire array is determined.
 3. The monitoreddeicing system according to claim 1, wherein the monitored deicingsystem is disposed along an airfoil.
 4. The monitored deicing systemaccording to claim 1, the signal wire comprising a carbon fiberfilament.
 5. The monitored deicing system according to claim 1, thesignal wire comprising a nickel-chromium alloy.
 6. The monitored deicingsystem according to claim 1, the pneumatic deicer comprising: a forminglayer comprising an elastic fabric; a base layer comprising an inelasticfabric disposed parallel to the forming layer and normally inward of thebase layer; and a boot seam connecting the forming layer and the baselayer.
 7. The monitored deicing system according to claim 6, furthercomprising a covering layer disposed normally outward of the forminglayer.
 8. The monitored deicing system according to claim 6, wherein thesignal wire is co-located with the boot seam.
 9. A monitored deicingsystem according to claim 6, wherein the boot seam comprises: a mainthread extending through the forming layer; and a bobbin threadextending through the base layer.
 10. The monitored deicing systemaccording to claim 9, wherein the bobbin thread comprises the signalwire.
 11. The monitored deicing system according to claim 9, wherein themain thread comprises the signal wire.
 12. The monitored deicing systemaccording to claim 9, wherein the signal wire wraps the bobbin thread.13. The monitored deicing system according to claim 9, wherein thesignal wire wraps the main thread.
 14. The monitored deicing systemaccording to claim 6, wherein the boot seam comprises the signal wire.15. The method of operating a monitored deicing system comprising:attempting, by a health monitor, to pass an electrical current through asignal wire disposed along a boot seam of a pneumatic deicer;evaluating, by the health monitor, a continuity of the signal wire inresponse to the electrical current; identifying, by the health monitor,that the signal wire lacks continuity in response to the evaluating; anddetermining, by the health monitor, that the boot seam has broken inresponse to the identification that the signal wire lacks continuity.